Download Installation Instructions

Important
Installation
Instructions
Product: Quicker Disconnects™
Part Number: PN 4100
Welcome
CONGRATULATIONS on purchasing a set
of new Quicker Disconnects™ from JKS
Manufacturing. We are committed to providing
you with the best products available and your
satisfaction is our first priority.
PLEASE READ these Installation Instructions
carefully, and save them for future reference,
as they contain important installation and
maintenance information.
JKS Quicker Disconnect Installation
Parts
NOT COMPATIBLE WITH aftermarket
swaybars. Install product with Original
Equipment swaybar only.
SOME VEHICLES MAY REQUIRE extended
front brake hoses or other modifications to
compensate for additional suspension travel.
NEVER DISCONNECT swaybar when
operating vehicle on public roads.
WHEN DISCONNECTED, the Quicker
Disconnects must be completely removed
from the vehicle and the swaybar must be
secured to prevent interference with other
suspension components or axle.
Tools Required
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Metric/Standard Socket Wrench Set
Torque Wrench
15/16” Open-End Wrench
#1 Philips Screwdriver or Small Punch
Medium Strength Threadlocker
Angle Measuring Tool
Welder
Paint Removal Tool
Black Spray Paint
Grease Gun with Zerk Fitting Coupler
Wheel Bearing Grease
PN 4100
A
B
C
D
E
F
G
H
I
J
K
L
M
1/2” x 1-3/8” NF GR5 Bolt
Spherical Bushing
Upper Stainless Steel Post
Click Pin
Press-In Grease Zerk
Grease Zerk Cap
Upper Male Threaded End
Lower Female Threaded End
1/2” Lock Washer
Weld-on Tab
1/2” NF Nylock Nut
Lower Stainless Steel Post
5/8” Jam Nut
Page 1 of 3
Installation
‰ 1. REMOVE ORIGINAL EQUIPMENT
(OE) SWAYBAR LINKS
 Remove front swaybar drop links and mounting
hardware per the factory service manual
instructions for your vehicle.
‰ 2. INSTALL UPPER TAPERED POST
‰ 3. DETERMINE MOUNTING LOCATION
FOR WELD-ON TAB
It will be necessary to weld the lower mounting tab
directly to the front axle housing. The base of the tab can
be positioned in the 2-, 3-, or 4-o’clock configuration as
viewed from the passenger side (8-, 9-, or 10-o’clock
from the driver side). HINT: The position of the mounting
tab will depend on the vehicle and amount/type of
suspension lift installed.
 Choose the configuration for the Lower
Mounting Tab that allows the Quicker
Disconnect to be installed as close to vertical as
possible. Length of Quicker Disconnect may be
adjusted as long as it does NOT exceed
Maximum Length of 9-3/8” (measured from
bushing centers).
 Mark the location on the axle tube where Weldon Tab (J) will be installed.
‰ 4. MOUNT WELD-ON TAB TO
 Mount the tapered Upper Stainless Steel Post
AXLE TUBE
(C) on outboard side of the swaybar, ensuring
small Click Pin holes are horizontal or parallel
with the ground.
 Remove tab and post assembly from Lower
End (H) of Quicker Disconnect and
disassemble.
 Apply medium strength threadlocker to the tip of
1/2” x 1-3/8” Bolt (A).
 Remove paint from axle tube where Weld-on
Tab (J) will be mounted and clean area
thoroughly.
 Weld lower mounting tab to axle tube so that
Stainless Steel Post – when installed – is
horizontal or parallel with the ground.
 Paint Weld-on Tab (J) and any bare metal on
axle tube with spray paint to prevent corrosion.
‰ 5. INSTALL LOWER TAPERED POST
 Secure tapered post to swaybar by inserting the
1/2” x 1-3/8” Bolt (A) and 1/2” Lock Washer (I)
from the inboard side and tighten to 65 ft-lb.
using a torque wrench.
HINT: For easiest operation, the tapered
mounting post should point forward as
illustrated in the 2- or 4-o’clock configuration.
Alternatively, a perpendicular mounting position
(as illustrated in the 3-o’clock configuration)
may also be utilized in tight clearance
applications.
 To determine the proper location for the lower
HINT: A small Philips head screwdriver or
punch inserted into the Click Pin hole will
enable you to prevent the Stainless Steel Post
from rotating when tightening the mounting bolt.
JKS Quicker Disconnect Installation
mounting tab, temporarily slide the Upper End
(G) of Quicker Disconnect onto the Upper
Stainless Steel Post (C) and adjust angle of
swaybar to Acceptable Range (0°-10°).
HINT: Refer to Step 6 on next page for
illustration of swaybar angle.
 Re-insert threaded end of Lower Stainless Steel
Post (L) into Weld-on Tab (J). Tapered end of
post must point forward or outboard, depending
on the mounting configuration chosen.
 Secure Stainless Steel Post (L) with 1/2” Nylock
Nut (K), ensuring small Click Pin holes are
horizontal or parallel with ground.
 Tighten 1/2” Nylock Nut (K) to 65 ft-lb. using a
torque wrench. HINT: A small Philips head
screwdriver or punch inserted into the Click Pin
hole will enable you to prevent the Stainless
Steel Post from rotating when tightening the
mounting bolt.
 Temporarily insert the threaded end of Lower
Stainless Steel Post (L) into Weld-on Tab (J)
and secure with 1/2” Nylock Nut (K). Slide tab
and post assembly into Lower End (H) of
Quicker Disconnect.
PN 4100
Page 2 of 3
‰ 6. SET QUICKER DISCONNECT
LENGTH
‰ 7. INSTALL QUICKER DISCONNECTS
 Slide Upper End (G) of Quicker Disconnect onto
 Adjust the length of your Quicker Disconnects
until swaybar is at the Ideal Angle or within
Acceptable Range. Vehicle must be at normal
ride height and located on level ground.
the Upper Stainless Steel Post (C) and Lower
End (H) onto Lower Stainless Steel Post (L).
YJ Wrangler
PN 4100
9-3/8”
CJ5/CJ7/CJ8
PN 4100
9-3/8”
If swaybar does not rotate freely, remove from vehicle,
clean and apply rubber lubricant to chassis-mounted
bushings, and reinstall.
 Insert Click Pins (D) as illustrated to secure.
Maintenance
Part
Maximum Ideal Swaybar Angle
Number Length *
(Acceptable Range)
Vehicle
Troubleshooting
It is important to lubricate Quicker Disconnects frequently
for the first three (3) months after installation to evacuate
contaminants that may build up during break-in period.
5°
(0°-10°)
5°
After break-in period, Quicker Disconnects should be
lubricated regularly as part of vehicle maintenance
schedule.
(0°-10°)
IMPORTANT: DO NOT exceed Maximum Length
(measured from center-to-center of bushings)
indicated for your part number.
Regular cleaning with pressurized water is
recommended to maximize ease of operation and
reliability. Always lubricate afterwards to evacuate any
moisture.
IMPORTANT: When properly installed, the ring on
the Click Pin will “snap” against the shaft of pin.
When installed backwards, the ring does not fit
snugly against shaft.
© 2009 JKS Manufacturing, Inc & Aftermarketing, LLC
Revision Date 8/5/2009
‰ 8. LUBRICATE QUICKER
 Once adjusted, lay Quicker Disconnects on a
flat surface and tighten Jam Nuts (M) firmly
against the Lower Ends (H).
IMPORTANT: Bushing cradles at both ends of
Quicker Disconnect must remain parallel with their
respective mounting posts when Jam Nut is
tightened.
JKS Quicker Disconnect Installation
DISCONNECTS
 Lubricate all Grease Zerk fittings (E) on the
Quicker Disconnects immediately after
installation using common wheel bearing
grease or equivalent.
PN 4100
Page 3 of 3